Spray coating of 2D materials in the production of antifouling membranes for membrane distillation

Membrane surface coatings with 2D materials have been shown to exhibit antifouling properties for water-treatment applications; however, synthesis methods currently based on vacuum filtration are not easily scalable. This study describes a scalable method for coating membranes with a range of 2D materials including graphene oxide (GO), hexagonal boron nitride (hBN), molybdenum disulphide (MoS2) and tungsten disulphide (WS2). Isopropyl alcohol solutions containing each class of the 2D flakes were spray-coated onto commercial polyvinylidene fluoride (PVDF) using a pyrolyser. The nanomaterials were secured with polydopamine (PDA) as a crosslinker in a method that could easily be integrated into a scalable roll-to-roll process. Changes in morphology, surface roughness, hydrophobicity, mechanical durability and chemical composition were evaluated using scanning electron microscopy, atomic force microscopy, contact angle, tensile strength measurements and Fourier-transform infrared spectroscopy. The 2D nanomaterials-coated membranes were tested in membrane distillation (MD) experiments over 72 h and compared to pristine PVDF and PDA/PVDF membranes. Salt rejection and MD performance stability were evaluated using feedwaters with high concentrations of humic acid (150 ppm) and paraffin oil (200 ppm) simulating simple organic wastewater from oil and gas extraction. The flux decline ratio was measured in terms of percentage permeate loss per hour (%/h), to allow for future comparisons with studies with different experimental times. The pristine PVDF membrane failed after 10 h by pore-wetting due to fouling while the PDA/PVDF membrane had the largest flux decline ratio (0.3 %/h). The membranes coated with GO and hBN had flux decline ratios orders of magnitude lower (0.0021 ± 0.005 and 0.028 ± 0.01 %/h, respectively). All membranes had a high salt rejection (>99.9 %). The GO-coated membrane was the only membrane type that was able to treat both surfactant-containing and foulant-containing feedwaters. The improved performance is attributed to the decrease in both surface roughness and hydrophobicity, which reduces the adsorption of foulants onto the membrane surface. This work shows a facile, scalable method to overcome fouling limitations in MD.